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An experimentally verified useful new model for reactive sputtering is presented. By considering the total system (target erosion, gas injection, chamber wall deposition, reactive gas gettering at all surfaces, etc.) during deposition it is possible to evaluate quite simple relationships between processing parameters. We have expanded earlier treatments to include these phenomena. The model involves that gettering of the reactive gas takes place at the target and at the walls opposite to the target. Arguments are also presented for how the sputtered materials (elemental target atoms and the formed compound) contribute to the formation of the surface composition of the walls opposite to the sputtering electrode. The mass flow of the reactive gas has been chosen as the independent parameter in this presentation. Results for partial pressure and sputter rate are presented. The theoretical values are compared with experimental results from reactive sputtering of TiN. It is also pointed out that the calculated values agree extremely well with results presented in the literature by several other authors.

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The etch rate of silicon, during reactive ion etching (RIE), depends on the total exposed area. This is called the loading effect. However, local variations in the pattern density will, in a similar way, cause local variations in the etch rate. This effect is caused by a local depletion of reactive species and is called the microloading effect. Silicon wafers patterned with silicon dioxide have been etched in order to study the microloading effect. The pattern consists of a large exposed area and narrow lines at different distances from the edge of the large area. This arrangement makes it possible to study how the distance from the large area, which depletes the etchants, influences the etch rate. The influence of different processing parameters like, e.g., pressure, gas flow rate, and flow direction on the microloading effect have been investigated. It has been found that the microloading effect is small (<10%) compared to other pattern dependent nonuniformities. It is also shown that the nonuniformities caused by the microloading effect can be decreased by, e.g., decreasing the pressure or increasing the gas flow rate.

The electrical, optical, and mechanical properties of a compound film depend strongly on the composition of the film. Therefore, it is interesting to study a wide variety of compositions of many new compound materials. Reactive sputtering is a widely used technique to produce compound thin films. With this technique it is possible to fabricate thin films with different compositions. However, it has not yet, to any great extent, been possible to predict the composition of the sputtered film. In this article we will present a model that enables us to predict both sputtering rate and film composition during reactive sputtering. The results point out that there exists a very simple linear relationship between processing parameters for maintaining constant thin-film composition in the reactive sputtering process. Based on these results, it is possible for the first time to combine information of both sputtering rate and film composition into the same graphical representation. Access to this new and simple graphical representation may eliminate much of the ‘‘trial and error’’ work that earlier has been associated with the reactive sputtering process.